Industry

Crusher, conveyor and plant data with remote site monitoring for mining

We collect tonnage, downtime and equipment health data from crushing, screening, conveying and processing plants and move it reliably even from poorly connected sites.

Let's talk about your project → What we deliver

Our clients

Siemens
Anadolu Isuzu
BSH
Tofaş
Toyotetsu
Martur
Turkcell
Vodafone
Doğadan
Pakmaya
Bross
Abdi İbrahim
Nobel İlaç
Plastimak
Dalgıç Kalıp
Barbaros Motor
Magneti Marelli
Rözmaş
Sanel

Mine sites are far from town, network links are weak and equipment works in harsh conditions. An unplanned stop of the crusher, the main conveyor or a mill cuts the whole plant's tonnage, yet the reason and duration of those stops often stay in the shift log.

VOLSOFT reads data from the PLCs of crushing, screening and processing plants, belt scales and motor protection relays without touching control logic. Tonnage, run hours, stop reasons, motor currents and temperatures are collected on site and sent to the central system.

When a remote site loses its link, data is buffered at the edge and sent in full when the connection returns. Every project is built on Proxus.

What we deliver

Mining

Tonnage and production tracking

Tonnage from belt scales and the truck weighbridge is reported by shift, product and stockpile.
Crusher and conveyor downtime

Run and stop states of crushers, screens and conveyors are read from PLCs, stop reasons are classified and plant availability is calculated.
Equipment condition monitoring

Motor current, bearing temperature, vibration and belt misalignment are watched, and threshold breaches go to maintenance as alarms.
Remote site connectivity and buffering

When a cellular or satellite link drops, data is stored on site and sent in order when the link returns.
Energy consumption

Energy use of crushers and mills is metered and energy per ton is reported.

Processes we work on

Where the data starts in mining

Primary and secondary crushers
Conveyor belts and belt scales
Vibrating screens
Ball and rod mills
Flotation and beneficiation
Pumping and dewatering stations
Truck weighbridges and stockpiles
Underground ventilation fans

How a project runs

From discovery to live, step by step

01
Site survey

Plant PLCs, scales, motor protection devices and site network links are reviewed on site.
02
Edge and connectivity design

The on-site collection point, buffering and the path to the central system are designed around existing hardware or hardware the client chooses.
03
Pilot plant

Tonnage, downtime and condition monitoring go live at one crushing and screening plant, and the data is checked against shift records.
04
Rollout and support

Further plants and sites are added, operations and maintenance teams are trained and remote support is provided.

Built on Proxus

Proxus runs at the edge on remote sites, buffers data locally when the link drops and delivers it in full to the central system when the connection returns.

Proxus is the industrial data platform built by the VOLSOFT team.

Proxus offline operation ↗

Frequently asked questions

Common questions

How are conveyors and crushers monitored in mining?

Conveyor and crusher monitoring reads run and stop states from plant PLCs, tonnage from belt scales and current and temperature from motor protection devices. The data is recorded with stop reasons and shifts, and plant availability is calculated.

Is data lost at mine sites with weak connectivity?

No. Data is buffered at the edge on site and sent to the central system in order when the link returns. Local site screens can keep working without the connection.

What data is used for condition monitoring of mining equipment?

Motor current, bearing and winding temperature, vibration, belt speed and misalignment sensors are the most common. Where sensors are needed, existing hardware or hardware the client chooses is used; VOLSOFT does not sell devices.

Can tonnage data be sent to the ERP?

Yes. Belt scale and weighbridge data can be passed to the ERP and reporting systems by product, stockpile and shift.

How long does a monitoring project take at a mine site?

It depends on the number of sites and plants, the existing automation and the connectivity. Projects usually start with a pilot at one crushing and screening plant, and the scope is set during the discovery call.